ANUAL SERVICE M

RIGHT CRANKCASE COVER

REMOVAL

Remove the following:

- Brake pedal (page 16-24)

- Right engine guard (page 3-5)

Drain the transmission oil (page 4-23).

Drain the coolant (page 7-7).

Remove the bolt and kickstarter pedal.

Remove the bolts, water hose joint and O-ring.

BOLT/KICKSTARTER PEDAL

Loosen the right crankcase cover bolts in a criss­cross pattern in two or three steps.

Remove the bolts, hose guide, hose clamp and right crankcase cover.

BOLT/HOSE CLAMP

Remove the water by-pass pipe and O-ring. Remove the gasket and dowel pins.

Check the kickstarter spindle oil seal for deteriora­tion or damage.

Apply grease to the kickstarter spindle oil seal lips.

INSTALLATION

install a new O-ring onto the by-pass pipe. Install the by-pass pipe into the crankcase.

*3* O-RING

Install the dowel pins and new gasket.

DOWEL PINS

Install the right crankcase cover while engaging the water pump shaft securely with the balancer shaft tab.

Install the hose clamp, hose guide and right crank­case cover bolts.

Tighten the right crankcase cover bolts in a criss­cross pattern in two or three steps.

BOLT/HOSE CLAMP

Install a new O-ring onto the water hose joint.

O-RING

Install the water hose joint to the water pump cover and tighten the bolts securely.

Install the kickstarter pedal and tighten the bolt to the specified torque.

TORQUE: 38 N-m (3.9 kgf m, 28 Ibf ft)

Install the following:

- Right engine guard (page 3-5)

- Brake pedal (page 16-24)

Fill the system with the recommended coolant and bleed the air (page 7-7).

Fill the transmission with the recommended trans­mission oil (page 4-22).

Start the engine and check for oil and coolant leaks.

CLUTCH

CLUTCH REMOVAL

Remove the brake pedal (page 16-24). Remove the bolts, clutch cover and O-ring.

Remove the clutch spring bolts in a crisscross pat­tern in two or three steps.

Remove the clutch springs.

Remove the clutch pressure plate.

PRESSURE PLATE

Remove the washer, needle bearing, clutch lifter and lifter rod.

LIFTER ROD

Remove the eight clutch discs and seven clutch plates.

Bend the tab of the lock washer away from the lock nut.

Remove the clutch center lock nut using the special

tool.

TOOL.

Clutch center holder 07724-0050002 or

equivalent com­mercially avail­able in U. S.A.

Remove the thrust washer and lock washer.

Remove the clutch center.

CLUTCH CENTER HOLDER

Remove the right crankcase cover (page 11-5). Remove the thrust washer and clutch outer.

THRUST W

Remove the needle bearings and clutch outer guide.

Remove the bolts, drive sprocket cover and spacer.

Disconnect the clutch cable from the clutch lifter lever.

Remove the bolt, stay and clutch lifter lever from the left crankcase.